The technique, according to GEFERTEC, promises to eradicate waste with “nearly 100% material utilization,” and cost savings of “up to 60% versus conventional manufacturing.”

In total, the company has four 3DMP machines in its portfolio:

– The arc603: a 3-axis machine capable of creating components up to 3 m³, with a maximum mass of 3000kg.
– The arc605: a 5-axis machine with a maximum capacity of up to 0.8 m³ and 500 kg mass.
– The arc405: 5-axis, 0.06 m³ capabilities and a maximum mass of 200 kg.
– And the arc403, the 3-axis machine which has just been installed by Airbus.

The process of producing a finished part with 3DMP follows 4 main steps: digital CAD/CAM design, manufacturing/3D printing, 3D scanning/metrology, and milling.

Inside a 3DMP 3D printer. Photo via GEFERTEC

More eco-efficient flight

Airbus and BIAS’s arc403 3D printer has been provided by GEFERTEC as part of the Regis Project, under the German government’s Federal Aviation Research Programme (LuFo).

In the Regis Project, GEFERTEC’s 3DMP process will be qualified for production-level manufacturing in the aerospace industry by the year 2021.

The aerospace certification race

Other metal 3D printing technologies working for aerospace qualification include Norsk Titanium Rapid Plasma Deposition (RPD) method, which was used to make Boeing’s first structurally-supportive, additive-manufactured titanium part for a commercial airline. Though certified for installation aboard the 787 Dreamliner, the RPD 3D printed part was subject to a point design qualification from the Federal Aviation Administration (FAA), relating only to that part’s specific geometry. The next step would be to achieve certification for design allowables using the RPD process.

Beau Jackson is Senior Journalist at 3D Printing Industry. With a longstanding commitment to the site's content, she is credited with producing more articles than any other author in its history. Well-versed in the latest 3D printing research and legal/regulatory challenges, her repertoire spans aerospace, automotive, maritime, medical and creative industries. She is a keen speaker and active representative of the company at key additive manufacturing events.